In September, ENERGAS celebrated its 12th anniversary. The team of the company is confidently moving towards the further improvement of engineering excellence. After all, it is well known that there is no limit to professional growth.



It is no coincidence that we focus on engineering professionalism. It is concentrated in the inherent talents of ENERGAS employees, their abilities, which are revealed in everyday work, in work on the development of theoretical knowledge and practical skills. It is how new experience is gained, which is necessary to create and implement integrated gas treatment and gas supply projects. It should be noted that 76% of the total number of ENERGAS employees are licensed engineering specialists.

The leading role of engineering professionalism in the activities of ENERGAS is illustrated by the figures and facts of the production report, which is prepared annually for the company's birthday.

TWELVE YEARS OF DEVELOPMENT. RESULTS AND PERSPECIVES

ENERGAS LLC is the head management company of the ENERGAS Companies Group, whose enterprises operate under agreed goals and objectives, have professional specialization in the field of gas treatment and bear solidary joint responsibility for the quality of their work.

Since 2007, we have implemented 150 projects and delivered 290 compressor and multifunctional units for complex gas treatment of various types and compositions. The total nominal capacity of these plants is 3,896,393 m3 / h, and the total operating time has reached the level of 11,573,910 hours. We add that the ENERGAS Companies Group is 36 regions of supply in Russia and neighbouring countries, with a maximum distance of operating sites of 7,704 km.



In the oil and gas industry, ENERGAS equipment at 46 fields treats various types of gas: associated petroleum, natural, condensate de-ethanization gas, cenomanian water gas. The units operate here at 63 facilities. These are: auxiliaries power supply complexes and power plants; oil treatment plants; oil processing and pumping shops; oil verification departments; booster pump stations; main transfer pumping stations; preliminary water removal units; central production facilities; oil and gas gathering facilities; terminal separation units; condensate de-ethanization units; condensate stabilization units; acceptance points; transportation systems of liquid hydrocarbons; complex gas and condensate treatment plants.

In the electric power industry, ENERGAS equipment provides fuel gas for 186 power units operating in a simple, cogeneration, combined or tri-generation cycle. The total electrical capacity of the conjugated power units exceeds 6,200 MW. ENERGAS gas treatment units function with generating equipment of leading domestic and world manufacturers: UEC-Gas Turbines and UEC-Saturn, UEC-Perm Motors and UEC-Aviadvigatel, Kazan and Ufa Motor-Building Production Associations, Nevsky Zavod, Russian Gas Turbines, Power Machines, Alstom, Turbomach, Centrax, Solar, Pratt & Whitney, Rolls-Royce, Kawasaki, Cummins, Wartsila, Siemens, General Electric.

Thus, over the years of development in its market segment, ENERGAS has achieved a reputation as a leading Russian manufacturer and supplier of technological equipment for gas compression and treatment (Upstream, Midstream). The ENERGAS Group carries out an entire cycle of projects implementation: designing, production, delivery, installation, commissioning, testing, training of customer’s personnel, service maintenance, repair, modernization and complex reconstruction of equipment.



EXAMPLES FROM THE PRODUCTION REPORT FOR THE PERIOD 10/2018 - 09/2019

Each ENERGAS project is unique and has features associated with the operating conditions of the equipment, the type and composition of the source gas, and the specific requirements of the customer. At the same time, they are united in applying the most effective engineering solutions and design developments, which have been repeatedly tested in practice. This applies to the configuration of gas treatment plants and systems with the primary and additional equipment, options for its placement at the facility, the principles of automated control and monitoring, and the provision of block modules with habitability and safety systems. Let's note some examples from the new production report.

System for recovery of APG at Vyngapur field (Gazpromneft-Noyabrskneftegas)

The system for recovery of APG of low oil separation stages has been commissioned at Preliminary Water Removal Unit (PWRU; the BPS-2 area). The basis of this system is ENERGAS vacuum compressor station. VCS performs compressing low-pressure (0.001 MPa) APG of the end stage and its feeding, after combining with gas of the first separation stage, to the main compressor station.

Vacuum CS is made on the basis of oil-filled screw compressor; its rated capacity amounts to 1,500 m3 / h; gas flow is controlled by a special two-level regulation system. VCS operates in an automatic mode. Local ACS is integrated with the upper level of APCS of BPS-2.

VCS was designed taking into account extreme operating conditions (minimum air temperature – minus 59°C, average temperature of the coldest five-day period – minus 50.5°C). Special alloys and anti-corrosion materials were used in the production. It is housed in its own all-weather enclosure equipped with life support systems (heating, ventilation, and lighting) and safety systems (fire detection, gas detection, alarm, fire fighting).



Previously, ENERGAS Group supplied vacuum compressor stations to a number of other facilities of JSC Gazpromneft-NNG located at Yamal. These are BPS-1 and CPF BPS-3 of Vyngapur field, OPPS of Vyngayakha field and BPS-2 of Ety-Pur field.

Starting compressor unit for the GTPP of East-Perevalnoye field (LUKOIL-West Siberia)

Previously, this CU was in long-term storage at the Gezh field. At GTPP, the unit was upgraded taking into account the new operating conditions. This task was solved by specialists of ServicENERGAS LLC, who carried out restoration works, upgrade of the oil system and replacement of main component of the unit, a screw oil-filled compressor.

The new aggregate was also equipped with a system for monitoring the temperature of the sliding bearings and a system for monitoring the axial shear of the compressor screws. There was installed new software, connected and configured automated control system of CU. Local ACS is integrated with the upper level of the APCS of the gas turbine power plant.

The main generating equipment of the GTPP-28 consists of four Ural-6000 power units (based on GTU-6P) with capacity of 6 MW each. Starting compressor unit with productivity of 2,000 m3 / h provides final treatment, compression and supply of associated petroleum gas under pressure of 1.6 ... 1.8 MPa to the starting Ural-4000 power unit, made on the basis of the GTU-4P gas turbine unit with capacity of 4 MW. The Ural-4000 and Ural-6000 were created by the companies UEC-Aviadvigatel and UEC-Perm Motors.



Gas treatment system for the GTU-TPP in Yelabuga city (IED-holding)

The new GTU-TPP built in Tatarstan with an electrical capacity of about 20 MW and a thermal capacity of 28 Gcal / h consists of 4 Solar gas turbine units of the Taurus 60 GS type and 4 waste-heat boilers. Turbines fuel is natural gas.

Designed parameters of gas for purity, temperature, pressure and flow rate are provided by the ENERGAS gas treatment system. GTS comprises a gas treatment station (block-type gas purification unit - BGPU) and a booster compressor station (BCS).

BGPU is a typical example of a compact multifunctional unit in the basic configuration. All process equipment is integrated on a single frame. The productivity of unit is 8,240 m3 / h, the small gas flow rate is due to the low capacity of conjugated gas turbines.

In accordance with the project, BGPU provides gas purification from solid particles and droplet moisture to the turbine manufacturer's design requirements, gathering of trapped liquid into a drainage tank with subsequent transfer to a mobile vessel or special transport, gas flow measurement, determination and recording of gas composition and its changes, determination of calorific value, gas dew point measurement.

After preliminary treatment, the gas is directed to the BCS, consisting of two screw-type units. The BCS compresses and feeds fuel gas to the turbines at the design pressure of 1.65 MPa. The process scheme of the BCS also provides for the maintaining of a set gas feeding temperature to the GTU-TPP.



Booster compressor units at CSLS of the South-Vatlor field (Surgutneftegas)

These BCUs are designed for pumping APG of the first separation stage coming from the booster pump stations of the following fields of PJSC Surgutneftegas: South-Vatlor, Vatlor, Suryogan, Verkhnekazymskoye, field named after I.N. Logachev.

The units, created on the basis of screw oil-filled compressors, continuously implement a final purification, compression and feeding of associated petroleum gas to the external gas pipeline at pressure of 2.2 MPa. The capacity of each BCU is 10,000 m3 / h.

At present, in the oil and gas segment, ENERGAS Group has commissioned 70 process units at gas gathering and transportation facilities, and 74 more units treat APG as fuel for autonomous power supply complexes of the fields.



Comprehensive gas treatment system for CCGT units of Pregolskaya TPP (Kaliningrad generation)

On March 2019, the launch of Pregolskaya thermal power plant with capacity of 455.2 MW was held. This largest facility of the new Kaliningrad generation consists of four combined-cycle power units, each of which includes 6F.03 gas turbine (Russian Gas Turbines), generator (Elsib), steam turbine (Power Machines), waste-heat boiler (Machine-Building Factory of Podolsk).

Fuel supply for TPP’s power generating units is provided by comprehensive gas treatment system of ENERGAS: gas treatment station (GTS), booster compressor station, and control module.

Multiunit GTS with a capacity of 106,000 Nm3 / h was manufactured by ENERGAS under a special project. The process unit consists of several block-boxes with equipment for various purposes, which are joined in a single building during mounting. The exceptions are the inlet filtration module and the condensate drainage subassembly (with a 10 m3 drainage tank), which have outdoor design on an open frame. In addition to the external elements, the GTS is equipped with a fine gas purification system, a commercial gas-metering unit (with ultrasonic flow meters), a gas heating subassembly, a reducing system, and a gas quality control module.

The booster station, consisting of four compressor units (CU), ensures gas supply to the power units if the pressure of the entering fuel gas is below the parameters set by the manufacturer of gas turbine equipment. The pressure on the delivery line can be provided in the range 2.6 ... 3.45 MPa. The unit capacity of CU is 35,500 Nm3 / h and is controlled by a two-tier regulation system. In addition to the main elements of filtration system, an additional filter for fine purification of gas is built into the block-module of each unit. The oil vapor analyzer in gas is installed on the common BCS outlet manifold (permissible level – no more than 0.5 ppm).

The local ACSs of the GTS and CUs are housed in the common control module (in a separate shelter), which is located on the gas facilities site. The module is based on modern microprocessor technology, using advanced software and switching equipment.



Small gas compressor unit at BPS-2 of the Konitlor field (Surgutneftegas)

In Khanty-Mansi Autonomous Area, a project to introduce a new type of gas compressor equipment for oil and gas production complex facilities has been implemented.

Upon completion of the pilot operation stage, the small gas compressor unit was put into routine operation at site of the booster pumping station No. 2. The SGCU became part of the low-pressure BCS and is designed for the pumping of associated gas with inlet pressure close to vacuum (0...0.09 MPa).

The SGCU has a set of advantages in its operating segment: transportation by standard trucks; low pre-start costs; minimum commissioning period; low operating and maintenance costs; affordable price.

The implemented engineering solution makes it possible not only to operate such units in a stationary mode, but also to consistently use one SGCU at different sites. It is important to note that when you move the unit to another facility, you do not need to re-adjustment.

The "small" compressors can operate at facilities without complex infrastructure. There is provided the way for connecting supply lines with flexible pipelines, which makes it possible to integrate SGCU without retrofitting the existing gas pipeline system.

At the Konitlor oil field, the unit with capacity of 350 m3 / h carries out fine purification of associated gas coming from the end separation stage, its compression and injection into transport gas pipeline under pressure of 0.85 MPa.

The fulfilled project has confirmed the operability and efficiency of this type of equipment in the climatic conditions of Western Siberia and its compliance with the operational requirements adopted at the facilities of Surgutneftegas.



Automated gas distribution station AGDS Aleksandrovka

AGDS Aleksandrovka carries out gas offtake from the main gas pipeline, purification, commercial metering, quality control, pressure reduction, heating and gas odorization before its transportation to a remote thermal power plant.

AGDS equipment: 2 filtration lines with coalescing filters; condensate drainage unit (with a tank of 3 m3); 2 measuring lines with ultrasonic flow meters; 2 shell-and-tube heat exchangers; 2 lines of reduction; calorimeter; moisture analyzer; odorization unit (with a tank of 2.1 m3 for odorant storage); automated control system; life support and safety systems; standby generator.

Preparation of the intermediate heat carrier for the gas-heating unit is provided by the block-modular boiler room, the enclosure of which is docked to the main AGDS module. The BMBR includes two water-heating boilers with a total useful thermal capacity of 1 MW.



Booster compressor station for the Grozny TPP (OGK-2)

After the launch of the 2nd power unit, the new thermal power plant has reached its full design capacity of 360 MW. The operating company of facility is PJSC Wholesale Generation Company OGC-2. The project has been implemented by the Gazprom Energoholding Group within the framework of a system of capacity supply agreements (CSA). The Grozny TPP is the final CSA project of the Group’s companies.

Each power generating unit with capacity of about 180 MW consists of SGT5-2000E gas turbine unit (GTU) manufactured by Siemens Gas Turbine Technology LLC. The main fuel for turbines is natural gas.

Designed parameters of fuel gas (on temperature, pressure, and flow rate) and its feeding to the GTU are provided by a booster compressor station consisting of three modular compressor units. The step-by-step commissioning of the BCS (erection supervision, start-up and adjustment works, own testing, comprehensive operability check as a part of the TPP, training of operating personnel) was conducted by leading engineers of the ENERGAS Group.

This equipment is the most powerful among all 233 gas compressor units of screw type, put into operation by ENERGAS specialists. The capacity of each booster compressor (rated – 34,200 kg / h, maximum – 39,240 kg / h) is up to 100% of the maximum flow of gas fuel per turbine. Two operating units give in total the necessary gas flow to two gas turbine power units. In this case, the third compressor is ready to be switched on by ATS (automatic transfer switch).



APG treatment facility for the power supply complex at Barsukovskoye field (Rosneft)

Barsukovskoye field (RN-Purneftegaz LLC, Rosneft), located in the Yamal-Nenets Autonomous Area, is equipped with autonomous power supply complex consisting of 10 Cummins gas-reciprocating units with a capacity of 1.5 MW each. The power plant built by LLC Alliance Generation supplies electricity to infrastructure and process sites of the field.

The fuel is associated petroleum gas. Its design parameters (in terms of purity, temperature, pressure and flow) are provided by ENERGAS fuel gas treatment facility (FGTF). This is a multifunctional complex, which comprises: gas filtration system with two-stage coalescent filters (purification rate is 100% for the liquid fraction and 99.9% for solid particles larger than 2 microns); condensate drainage module with underground tank; commercial gas-metering subassembly with ultrasonic flow meters; gas heating module based on a shell-and-tube heat exchanger; two-line reducing system; block-modular boiler room for the treatment of the heat carrier, including two boilers with a total thermal capacity of 0.19 MW.

FGTF was commissioned in June this year. The rated capacity of the facility is 5,000 m3 / h. Coefficient of operational reliability is 0.99. Assigned resource (lifetime) is 30 years.



Gas compressor unit for the test complex of UEC-UMPO gas turbine engines

In Bashkortostan, the test complex (TC) of PJSC UEC - Ufa Motor-Building Production Association carries out equivalent cyclic testing of AL-31ST gas turbine engines (GTE) used in gas pumping units and power plants.

The TC is equipped with a booster compressor unit (BCU) intended for uninterrupted fuel gas feeding to the testable GTEs according to the set parameters on purity, pressure, temperature and flow rate. BCU from ENERGAS compresses gas to the designed values (2.8…3.2 MPa) and feed it to the gas generator of drives in the process of their testing.

The unit was developed on an individual project – specially for operating in conditions of the high intensity of starts and shutdowns under various duration of testing. Taking into account the stringent requirements for the purity of fuel gas, filtration system in BCU is enhanced. In addition to the gas-oil filter separator of the 1st stage of purification and the coalescing (safety) filter of the 2nd stage, into block-module there is extra built inlet filter for fine purification of gas (degree of purification is 98% for contaminations of more than 5 microns and 100% for particles larger than 10 microns). Residual content of impurities in gas at the outlet of the BCU is not more than 2 ppmw (mg / kg). A gas cooler is integrated into the process flow diagram of the unit, which ensures the separation of the condensate and the stable maintenance of the fuel design temperature for gas turbine engines (up to +60°C).

Capacity of BCU is 6,500 m3 / h. Gas flow rate is controlled in the range from 0 to 100% of nominal. For this purpose, a special two-loop regulation system is applied. The first loop (control by the compressor spool valve) provides smooth, stepless capacity control in the range of 15-30% ... 100%, and to control capacity in the lower range it is combined with a gas recirculation system (second loop), which allows you to respond quickly and correctly on a sharp change in load during transient operating modes of conjugated GTE.



For efficient monitoring, management and safety of process procedures of the BCU is responsible full-completed two-tier automated control and regulation system (ACRS), which is integrated into APCS of the test bench. The first tier – BCU control module – is housed inside the block-box of the unit and separated from the process part by gas-tight fire-resistant partition. The second tier – a remote control (operator workstation, WKS) – is located in the control room of the facility.

Note that for ENERGAS Group this is the fourth similar project. Earlier, by specially designed compressor units there were equipped gas turbine's test benches of PJSC Proton - Perm Motors, JSC UEC - Gas Turbines and CJSC Nevsky Zavod.

Today, ENERGAS plans to develop new complex and large-scale projects based on highly efficient gas treatment equipment.

Industry-specific magazine "Neftegaz.RU"